Automotive wiring harness is the carrier of automotive energy, various signal transportation, connecting the central control components and automotive control units, electronic and electrical execution units, electrical components together, constituting the car’s electronic control system, is the car’s blood vessels and nervous system. If according to the layout in the car, the wiring harness can be divided into: body assembly wiring harness, engine wiring harness, instrument panel wiring harness, chassis wiring harness, roof wiring harness, door wiring harness and so on.
High-voltage wiring harness, as the main carrier of power output on electric vehicles, is one of the key components for the performance and safety of the whole vehicle. The new energy vehicle system contains low-voltage harness and high-voltage harness, of which the high-voltage harness system is a brand-new system under electrification, replacing the engine harness of traditional vehicles, mainly including high-voltage connectors, high-voltage cables, charging sockets and so on.
Because of the excellent electrical conductivity of copper materials, automotive high-voltage wiring harnesses are generally procured copper materials as a conductor. (20 ℃ environment, the resistance of copper is 0.0185 Ωmm2/m, aluminum resistance is 0.0294 Ωmm2/m). In the case of high current, the working temperature rise of copper wire is lower, on the one hand, it can reduce the heat loss during power transmission, on the other hand, the excellent thermal conductivity of copper material also ensures that the working temperature of high-voltage wiring harnesses is stabilized within the safety range. At the same time, due to excellent electrical conductivity, under the same load, the cross-sectional area of the copper wire can be smaller, which can effectively help the flexible arrangement of high-voltage wiring harnesses, including smaller turning radius (high-voltage wiring harnesses generally need to be more than the diameter of the wire harness more than 5 to 6 times); In addition, the finer wiring harnesses can reduce the bending stress, installation of wiring harnesses, connectors insertion and extraction force is smaller, to help reduce the difficulty of installation and maintenance to Improve the stability and reliability of the assembly; and, smaller cross-sectional area can help high-voltage wiring harnesses are flexibly arranged to fit the metal body grooves, corners, or close to the metal body layout to effectively reduce electromagnetic interference.
In addition to good electrical conductivity, copper as a high-voltage wire harness conductor material is another advantage of better tensile strength and bending properties. Copper metal has good mechanical properties, tensile strength of 200-240 MN/M2, elongation up to 50%, its good plasticity makes it easy to process, has a high plastic deformation capacity, can be calendered, extruded and stretched and other pressure processing methods made of a variety of shapes and sizes of the products, and the use of copper as a conductor of high-voltage wiring harness in the use of the process can withstand the vehicle traveling in the process of the occurrence of the Vibration and friction, with high reliability and longer service life.
